Work Instructions

Group: 09

Number: 237

Date: February 1989

SUBJECT:
INSPECTION OF TURBOCHARGER
MODELS 124 AND 126 WITH ENGINE 603.96
M.Y. 1986 AND 1987

1. Remove air filter housing.

2. Remove all engine encapsulation panels.

3. Loosen clamp at air flow sensor housing and remove air intake hose.





4. Remove partition wall (A, Figure 1).

5. Remove vacuum line (tr/vi/br) from EGR valve and vacuum line (tr/vi/bu) from air recirculating valve.





6. Remove clamp (B) from corrugated tube and remove EGR valve (60, Figure 2).

7. Loosen trap oxidizer from exhaust manifold and turbocharger. Remove support bracket. Remove trap oxidizer.

8. Check exhaust side of trap oxidizer for broken particles. If cracks and broken particles are found, replace trap oxidizer.

If particles are broken out of the trap, then the turbocharger must also be removed and disassembled.

9. Remove turbocharger.

9.1 Disassemble the turbocharger by securing turbocharger flange in a bench vise using vise jaw protective covers.





9.2 Mark position of turbine housing (Fig. 3). On KKK turbochargers, remove the air recirculating valve (waste gate) line. On Garrett turbochargers disconnect tie rod. Loosen and remove bolts and remove compressor housing.

Note:
In some cases it may be necessary to apply penetrating fluid to the bolts, loosen the bolts with a punch and then replace bolts.





9.3 Remove any foreign material from the turbine housing with a screwdriver and a shop air hose. Inspect turbine housing for damage.








9.4 Inspect the turbine vanes for damage.

9.5 Check turbine shaft for free movement. The turbine shaft should be easy to turn.

Note:
If any damage is determined during steps 9.3, 9.4 or 9.5, replace turbocharger.

9.6 Clean mounting surface and install turbine housing. Pay close attention to alignment marking from step 9.2.

9.7 Reassemble the turbocharger

On the Garrett turbo, disconnect the pressure line from the air recirculating valve and apply 1 bar of pressure to the valve element. Connect the tie rod and secure.

On KKK turbo, connect the pressure line.

Tightening torque for turbine housing: 15 Nm

10. Reinstall turbocharger and trap oxidizer in reverse order of removal.